Tool with intersecting die faces



Jan. 30, 1968 J. E. LYNCH 3,365,927

TOOL WITH INTERSECTING DIE FACES Filed 001:. 1,' 1965 2 Sheets-Sheet 1 IN VEWYJR.

AIM ms EwwARn Drum BYM,MY-%1 Jan. 30, 1968 J. E. LYNCH 3,365,927

TOOL WITH INTERSECTING DIE FACES Filed Oct. 1, 1965 2 Sheets--Sheet IN V/EN'I HR, JAMES EDWARD LYN H [53 M1,, M+W

United States Patent 3,365,927 TOOL WITH INTERSECTING DIE FACES James Edward Lynch, Harrisburg, Pa., assignor to AMP Incorporated, Harrisburg, Pa. Filed Oct. 1, 1965, Ser. No. 491,905 Claims. (Cl. 72-416) This invention relates to a crimping tool of the type utilized to terminate portions of electrical cable to electrical connectors and particularly to a tool having intersecting die faces adaptable for use with coaxial connectors.

Many types of electrical cable contain more than one conductor. For example, the typical construction of coaxial cable includes a center solid or stranded conductor surrounded by a dielectric medium and an outer conductor of metallic tubing, foil or braid. Crimpable connectors for cable of this type call for separate crimps applied to terminate conductive portions of the connector to the different conductors of the cable, These crimps are usually of substantially different characteristics and are of different sizes. For example, the crimp applied to the cable center conductor is typically relatively small in diameter and involves deformation of a thinned wall center contact member onto the center conductor. The crimp terminating the cable outer conductor is typically accomplished by a controlled deformation of a relatively thin wall ferrule down over the cable outer conductor and over a back-up sleeve of the connector; which parts are many times larger in diameter than the center contact member or the cable center conductor.

A common prior art answer to the foregoing has been to provide separate tools for the diiferent crimping operations. An alternative prior art solution has been to provide in a single tool multiple crimping dies axially spaced apart and arranged so as to be separately usable in performing the different crimps for a given connector. Both of the foregoing approaches have shortcomings. The former is expensive in terms of multiple tooling for any given connector design and in terms of assembly time wherein one must manipulate at least two different tools to perform a single termination of a connector to a cable. The latter requires a tool construction which is inordinately large and heavy.

In certain applications for a given size of electrical cable, distinctly different connector designs are employed. For example, in an application wherein the signals handled are in the lower and mid-frequency range, a

connector is utilized which has relatively loose tolerances and accordingly, of low cost. In applications wherein the signals handled are of higher frequencies, as in the thousand megacycle range, the same size connector is made to tighter tolerances and is made to include design features which minimize, as far as possible, differences in diameter spacing of the conductive portions of the connector. This is done to preclude changes in characteristic impedance and other discontinuities causing signal loss. In these applications the crimp applied to the outer cable conductor is usually the same, but the crimp applied to the center conductor is made of loose tolerance or of careful tolerance, depending upon the performance called for. As developed, the prior art requires two or three tools to accomplish crimping operations for each connector size, even though the outer conductor crimp is identical in both sizes. This is again unhandy and expensive.

It is an object of the present invention to provide a crimping tool capable of accomplishing in a common die face structure, at least two substantially different types of crimps. It is another object to provide a die structure for crimping tools having intersecting dies surfaces for related unrelated crimping operation. It is still another ICC object of the invention to provide a novel tool for crimping operations providing an economy of width and die surface for multiple crimps of differently sized connector and cable components.

The foregoing shortcomings of the prior art are overcome and the foregoing objectives are attained in the present invention through a tool and die structure arranged and dimensioned to perform one type of crimp along a given axis and one or more different types of crimps along an axis perpendicular to the first mentioned axis. The die faces are dimensioned so that the presence of the first die surface does not affect the crimp achieved by the one or more die surfaces. The presence of the one or more die surfaces is made to improve the crimp resulting from the first mentioned die surface. The tool of the invention is embodied in this application in a hand tool, but it is fully contemplated that the tool may be used in pneumatic, hydraulic or electrically driven devices to the same advantage. The present application is related to a particular type of coaxial connector for coaxial cable. It is also contemplated that the features and advantages of the tool may be incorporated in tooling useful in other types of connectors, terminals, splices and the like wherein crimps of substantially different. characteristics are of necessity, or at least desirably, performed by the same tool structure.

In the drawings:

FIGURE 1 is a side view of the tool head of the invention containing the dies of the invention in the open position;

FIGURE 2 is a view taken from the right side of FIG- URE 1;

FIGURE 3 is a view of the opposite side of the tool as shown in FIGURE 1;

FIGURE 4 is an enlarged perspective of the upper and lower dies of the tool head of FIGURE 1;

FIGURE 5 is a plan view of the upper and lower dies of FIGURE 4;

FIGURE 6 is a perspective showing a coaxial connector and coaxial cable separated but having the components partially assembled thereon in preparation for crimping by the tool of the invention;

FIGURE 7 is a perspective showing the connector and cable of FIGURE 6 subsequent to termination by the tool of the invention;

FIGURE 8 is an elevational view of the tool head of the invention with the dies thereof in closure performing a crimp upon the center contact member of a coaxial connector; and

FIGURE 9 is a view of the tool head of the invention with the dies thereof in closure performing the crimp of the outer ferrule of the coaxial connector.

Referring first to FIGURES 6 and 7, there is shown a coaxial cable 50* and a connector 60 of the type served by the tool and die structure of the invention.

The cable 50 is of a typical construction including a center conductor 52 surrounded by a dielectric and insulating sheath 54, an outer conductor comprised of a braid 56 and an outer protective sheath 58. The coaxial connector 60 includes a forward connector structure which may be considered as standard. The rear part of this structure is comprised of a thin but rigid shell 62 serves as a backup member to receive the outer conductor 56 of the cable and to be terminated thereto by the deformation of a ferrule 66. The center conductor of the cable is terminated to a center contact member 64. The center contact member 64 is shown positioned on the cable center condoctor in FIGURE 6, prior to crimping and is shown poked home within the connector structure with the end thereof visible in FIGURE 7. FIGURE 7 represents the assembly of connector and cable after termination.

The center contact member 64 is typically of medium hard brass, screw-machined to define a bore capable of receiving the cable center conductor. In a high performance connector the center contact member 64 may include a humped portion as shown, which when deformed as by crimping takes up the outer surface configuration of the remainder of the contact member to prevent the occurrence of an indentation causing a discontinuity within the connector structure and resulting or incidental losses or degradation to the signal transmitted by the connector. In an alternative design for lower frequency applications the center contact member does not have such humped portion as an indentation is quite acceptable. In certain of these applications the indentation itself is utilized to lock the center contact member within the insulating insert of the connector. Within the same general dimensions a connector such as 6d may either be high performance or low performance, depending upon the overall tolerance carried in the structure and certain features such the humping of the center contact member or the lack thereof.

The outer ferrule 66 of the contact structure is in both of the aforementioned cases substantially identical. The ferrule 66 is comprised of a relatively thin, malleable material such as soft copper, tin plated for performance and appearance. The ferrule includes a forward portion of substantially constant diameter adapted to be deformed inwardly over the sleeve portion 62 of the connector to terminate the outer conductor 56 thereto. This sleeve portion as 66a is of a length to extend back over the cable outer sheath outboard of the end of 62 and to be deformed inwardly to grip the cable outer sheath 58 and support the cable against bending movements which might disturb the connection at 62. or at the center contact member 64. Outboard of the sleeve portion 66a is an enlarged portion 66b, which contains a seal such as an O-ring therewithin. In this particular embodiment the portion 66b is left undeformed during crimping, the seal being sized so as to be compressively loaded by insertion on the cable outer sheath 58.

The foregoing cable and connector structure thus represents the crimping application served by the invention tool and die structure now to be described.

Turning now to the tool and die structure of the invention, and referring to FIGURES 1-3, the assembly 10 represents the head of the tool of the invention. The assembly 10 is comprised of a C-shaped yoke 12 which is of the configuration shown in FIGURES 1-3. The yoke 12 is of a relatively heavy and rigid metallic construction. The C portion shown as having an opening 14 is provided to facilitate insertion of connectors for termination. There is further provided running along the length of 12 a machined-out slot 16 adapted to accommodate fixed and movable die structures within the assembly. The front face of- 12 and the upper portion of the recess 16 is covered over by a plate 18 anchored thereto by a number of screws 20. The lower portion of the plate 18 extends around and over the opening of the recess I6 to confine the lower and movable die structure, as shown in FIGURE 1. There is an additional plate 21 provided on the lower right-hand portion of 12 which is anchored as by a screw 23 to extend over and secure the lower movable die structure, within 16 on the other side. Depending from the lower part of 12 in grooves therein such as 17, shown in FIGURE 2, are links 22, 26, fastened for pivotal movement to 12 by pins 24 and 28, respectively. The links 22 and 26 are tied to the mechanism responsible for die movement. In US. Patent No. 2,765,688 there is a hand tool structure similar to that shown and a description of the operation of the mechanism is there given. Whether the drive be provided by a hand tool or by some pneumatic, hydraulic or electric drive mechanism, the operation is essentially the same. The links 22, 26 tie the head to the driving means and the actual drive is applied through the lower die member 3 0 which is slidable within the recess 16 in the lower portions thereof. This lower die structure includes a depending pin member 30a having an aperture 3-91) linked to the driving mechanism. Integral with 30a is an upper portion Ede which extends across the base of the member 36) and up on the right-hand side as shown in FIGURE 2. Nested within and anchored to Stlc are die members shown in detail in the lower portion of FIGURE 4. These die members are anchored to 300 by means of a pin 39:1. The assembly 3th is driven vertically within the recess In to close against an upper die assembly 34 shown in the upper part of FIGURE 4 in detail. The die assembly 34 is anchored by a pin 36, which is made to extend into and be anchored to the body of 12 in the inner portion of In as shown in FIGURE 2.

Die movement can be visualized by comparing FIGURE 1 showing the dies opened and FIGURE 8 showing the dies closed.

FIGURES 4 and 5 show the upper and lower dies in greater detail. The lower die 30 includes a number of die surfaces carried on the member 300 and fastened thereto by the pin 30d. These die surfaces include a relief Bile and sets of the surfaces 343 and 30g substantially parallel to each other and in a sense transverse to a further die surface 3011. The upper die includes mating die surfaces carried in a block 34a and in members fitted within recesses in the block and fastened thereto by pins such as 38. Beginning to the left of 34 there are die surfaces 341; and 34c, which correspond to die surfaces 30g and 30), respectively in the lower die half. A recess 34d corresponds to 36 in the lower die half. Transverse to the die surfaces just mentioned is a die surface 34c Which corresponds to the die surface 3011 in the lower die half.

The recesses 3tlc and 34d are positioned relative to the length of the ferrule 66 so as to cause a radial enlargement of the ferrule in between crimped down surfaces in the manner shown in FIGURE 7 between the right-hand crimp portions of zone C. This enlargement permits a relief left in the inner surface of the ferrule into which the cable may flow during deformation to better anchor and seal the termination against the entry of contaminants. The recess further permits some flowing of the cable material and of the metal of the ferrule to preclude an undue deformation of the cable in a zone outboard of the support of the sleeve 62 of the connector. It will be observed from FIGURE 5 that the recesses 30c and 34d extend fully across the die faces and thus fully around the ferrule 66 to accomplish the bulging as shown in FIGURE 9.

With further regard to the crimp applied to the ferrule es, the die surfaces 3% 30g and 34c, 34b also operate as relief which causes a rounded bulging of the ferrule material in the top half of the ferrule as shown in FIG- URES 7 and 9. This further relief has been found to be advantageous if controlled, to the approximate Width shown, to leave a substantial amount of the ferrule material deformed inwardly against the outer braid 56 of the cable.

The surfaces 30f, 30g, 340 and 34b permit a crimping of the center contact member to the center cable of the connector in the manner shown in FIGURE 8. In use, only one of the pairs of surfaces such as 30 and 340 in the lower and upper members are utilized for a given center contact member. As previously mentioned in certain connector designs one type of center contact struc ture may be utilized and in other applications another type of contact structure may be utilized. The die faces 30f, 34c serve for the one type and the die surfaces 39g, 34b serve for the other type.

In use the center contact member to be terminated is positioned as shown in FIGURE 6 upon the cable center conductor and then is inserted in the appropriate die surfaces as shown in FIGURE 8, with closure being.

the center contact member and the left-hand portions of the die surfaces in this instance merely serve to center and hold the end of the center contact member from being cocked or misaligned during positioning of the pin member with the tool and during the crimping operation.

In the event that a different type of center contact member is to be crimped onto the cable center conductor, the other die surfaces may be utilized in the same manner.

After the termination of the center contact member in the manner just described the cable is then poked within the connector structure with the outer conductor positioned over sleeve 62. The ferrule 66 is then brought up over the outer conductor 56 and the cable connector assembly is positioned within the tool with the ferrule resting against the surfaces 34e. The tool is then closed as shown in FIGURE 9 to result in the crimping of the outer ferrule.

In the foregoing manner a variety of different types of crim-ps may be accomplished with a single tool and structurally integral die structure. The tool and die structure is of a width less than tools heretofore available and thus is lighter, less expensive and to an extent more reliable than tools heretofore available.

Having described my invention in a mode intended as a preferred mode of practice, I now define it through the appended claims:

What is claimed is:

1. In a tool for terminating connectors to electrical cable the combination comprising a die housing including a fixed die and a movable die adapted for cooperative closure for crimping, means to drive said movable die in closure toward said fixed die, said fixed and movable dies each including a first die surface adapted to effect a controlled deformation of metal to terminate one portion of a connector to one portion of electrical cable and further each including substantially normal to the first die surface a second die surface adapted to deform metal to terminate the second connector portion to a second portion of cable.

2. The tool of claim 1 wherein the said first die sur face is formed of a given radius extending across each die and the said second die surface is formed in the material of the side walls of the die material defining the first die surface.

3. The tool of claim 2 wherein the said die housing includes a relief providing access to the said first die surface and a further relief normal to the first mentioned relief to provide access to the second die surface.

4. The tool of claim 1 wherein the said die housing is comprised of a C-Shaped yoke and the said means to drive said movable die enclosure toward said fixed die is pivotally affixed to the bottom of said yoke.

5. In a tool for crimping coaxial connectors to a coaxial cable, the combination comprising a tool head carrying fixed and movable dies, means to drive the said movable die toward and away from the fixed die to perform a crimping operation, the said fixed and movable dies each having a first set of die surfaces along one axis to effect one type of crimp to a connector and cable and having a further set of die surfaces formed therein at right angles to the said axis to accomplish a second crimping operation to other portions of a connector cable assembly.

6. The tool of claim 5 wherein the said first set of die surfaces are of a constant given radius and the said further set of die surfaces are of a substantially smaller radius than said given radius.

7. The tool of claim 5 wherein the said first set of die surfaces along one axis are of a relatively large radius to provide a crimp of a portion of the coaxial connector to the outer conductor of coaxial cable and the said further set of die surfaces are of a substantially reduced radius to provide a crimp of the center conductive portion of the connector to the center conductor of coaxial cable.

8. The tool of claim 7 wherein the said tool head includes the relief permitting access to one side of the said first set of die surfaces and the said further set of die surfaces are positioned in the one side of the die material defining the first set of die surfaces.

9. In a tool for terminating a connector to electrical cable of the type having differently sized conductors, the combination comprising a die housing including movable and fixed dies, means for operating said dies simultaneously in relative movement to accomplish crimping of different portions of said connector to said conductors, the said movable and fixed dies including first and second cooperative die surfaces, the first and second die surfaces being in a position to provide one crimp and the second die surface being positioned to provide a second crimp independent of the first die surface.

10. The tool of claim 9 wherein the second die surfaces are positioned in the side wall of the die material defining the first die.

References Cited UNITED STATES PATENTS 2,411,838 11/1946 Swengel 72410 CHARLES W. LANHAM, Primary Examiner.

RONALD D. GREFE, Examiner. 

1. IN A TOOL FOR TERMINATING CONNECTORS TO ELECTRICAL CABLE THE COMBINATION COMPRISING A DIE HOUSING INCLUDING A FIXED DIE AND A MOVABLE DIE ADAPTED FOR COOPERATIVE CLOSURE FOR CRIMPING, MEANS TO DRIVE SAID MOVABLE DIE IN CLOSURE TOWARD SAID FIXED DIE, SAID FIXED AND MOVABLE DIES EACH INCLUDING A FIRST DIE SURFACE ADAPTED TO EFFECT A CONTROLLED DEFORMATION OF METAL TO TERMINATE ONE PORTION OF A CONNECTOR TO ONE PORTION OF ELECTRICAL CABLE AND FURTHER EACH INCLUDING SUBSTANTIALLY NORMAL TO THE FIRST DIE SURFACE A SECOND DIE SURFACE ADAPTED TO DEFORM METAL TO TERMINATE THE SECOND CONNECTOR PORTION TO A SECOND PORTION OF CABLE. 